Filling automation system

ABSTRACT

An automated system for filling oil tankers and other equipment with different materials. The system comprises product/additive pumps, a section for delivering product/additive, and optionally an emergency control.

RELATED TECHNICAL FIELD

This invention is related with a filling automation system which will provide safe filling to oil tankers in refineries and filling terminals and provide correct and synchronized data records regarding the process from order stage to filling stage.

The invention can easily be adapted to many applications at refineries fuel storage and filling terminals. For instance, the applications such as filling of road oil tankers, injection of additives and markers, product transfer through pipelines, filling of train wagon, tanker and barge fillings at sea sales can satisfactorily be controlled by means of this invented system. The tankers which are filled from top and bottom in the oil tankers filling terminals/stations, white and black products, volumetric filling with meters, filling by weight via scales are easily supported.

CURRENT SITUATION OF THE TECHNIQUE

In prior applications, manual systems were used for the operations similar to tanker fillings in sea sales or train wagon fillings in product transfers through pipe lines or fillings of road tankers at refineries and filling terminals. A sequence of manual operations such as meter reading by the personnel in critical steps such as entry of filling data during filling or emptying operations or reading tare weight were used and in such a case this has caused many mistakes.

In regard to the systems applied in order to be able to make serial and fast filling, entry of the tare weight data read in the electronic scales manually by the filling personnel cause the system be slowed down and decrease the efficiency of it.

With advancement of the technology, computer technologies which are used in many sector of our days has also taken placed in the production/manufacturing sector and this provides benefit to the industrialists especially in the major fields such as planning, manufacturing and shipping, etc. Progress has been made in production technologies through using computer aided softwares, and so the industrial companies dealing with filling and distribution has started to implement the principle of getting maximum quality with minimum cost by decreasing all the unnecessary operations during the production stage even by minimizing all the troubles in the process.

When we looked at the current situation of the technique, it is seen that the patent document of No: TR2007 03661 is related with an automation system which is able to read “LPG cylinder information card” automatically labeled over the LPG cylinder, making the fillings of these cylinders automatically and removing the faulty/mis-produced cylinders from the conveyor line automatically.

In prior technique, an another patent related with the filling systems of No TR2010 00953 is related with “tanker monitoring system which is able to make pricing peculiar to customers. This system is a controlling and monitoring equipment which receives the filling and emptying data taken from meters of the tankers used in any kind of liquid transportation in highways through a serial communication interface and processes such data and transfer to central server over a GSM Modem.

Both of the above mentioned patents deal with innovations and automation subjects made for specific areas of the fillings of tankers or cylinders. No automation system is available presently which covers the process completely and provides correct and synchronized data entry of the operations from the order stage to filling. This invented filling automation system satisfy the needs in such sense, and provide monitoring of all the processes safely starting from entrance of the tanker from gate until exit from the gate.

PURPOSE OF THE INVENTION

The purpose of this invention is to provide making safe fillings at filling terminals, preventing wrong product filling, keeping the records of filling operations at computer media, synchronizing order and filling data by ensuring integration via ERP systems (such as SAP, LOGO, etc).

An another purpose of this invention is to ensure to keep the data to be recorded at filling operation, in another words, ensure data reliability.

Again an another purpose of the invention is to offer to the user an easy utilization facility.

Again an another purpose of the invention is to minimize project and operation costs.

EXPLANATION OF THE INVENTION

The invention is a filling automation system which comprises of firstly a section where the filling orders are accepted; product/additives pumps; a section where product and additive pumping automation is carried out and emergency halting is provided when necessary, a tanker filling section where tanker filling is carried out, pipe line filling section as well as alternative ship filling and wagon filling sections, a tank area where movements of tanks are monitored, a scale section where the weight of the product to be filled to the tanker is measured, a pipe line monitoring section in order to monitor pipe line where the product flows, a control room having a main server and backup server where daily meter activities, sales on tanker, customer, agent basis are monitored, retroactive reports are taken, day start and day end operations of all the fillings are monitored and remote access is provided.

Main computer (server) located in the control room used in this invented automation system is in active state and second computer is in passive state. The records processed by the automation will be stored in backup computer first and then database of main computer next and both of them will accommodate same data. Storage action will be made by using relational database properties. So, data security will be secured in a maximum level. Filling islands and tankers being filled are shown in the screen of the system graphically and in detail and which island, meter or delivery order have a problem are warned graphically and in color. The data is stored in Hard Disk Drive in case of power cut or due to another reasons.

Process steps of this invented tank filling automation system are as follows:

a. Order:

-   -   Order details are entered via order module.     -   The respective driver of incoming orders which are communicated         with ERP-DOS and similar communication programs are called for         filling via announce module. Relevant driver are directed to         filling island.     -   Driver (or operator) enters the PIN number written over the         Product Request Bill from display of meter. (Make his card be         read at card reading system)     -   Controls the meter PIN number via system and takes the concerned         information regarding the request.     -   Asks Tanker PIN code if necessary according to order type.     -   Asks Driver PIN code if necessary according to order type.     -   Asks compartment number.     -   Sets the product quantity regarding that COMPARTMENT         automatically.     -   Filling is started by pressing Start button.     -   Filling is continued by entering COMPARTMENT numbers again for         other product requests given in delivery note. If the filling         operation of the compartment is whatsoever finished by pressing         PRINT button, PIN number is asked again for other COMPARTMENTS.     -   If only one type product is going to be taken to the tanker,         only COMPARTMENT number is asked for 2nd and 3rd compartments.     -   After all the products written in the Product Request Bill is         delivered, filling computer compares the starting and ending         total quantities with given product quantity and in case of         error, locks the meter for intervention by responsible filling         personnel.     -   Filling islands and tankers being filled are shown in the screen         of the system graphically and in detail and which island, meter         or delivery order have a problem are warned graphically and in         color.     -   The authority to intervene to the problems are within the scope         of authorities and filling is finalized through computer screen         by halting the filling when required.     -   When meter communication is cut due to a failure, the values         already stored in the memory of the meter are read and related         tables are updated.     -   In case the program is shut down due to power cuts or other         reasons, data is stored in HDD.     -   Upon completion of the order without any mistake, tanker graphic         comes to its normal position on the meter screen.     -   The data of realized filling are transferred to concerned units         on product and compartment basis.     -   Product Delivery Receipt is given to tanker driver for         informative purposes while tanker is left.     -   The order is locked if any troubles is occurred in the execution         of work flow in filling terminal. User response is asked.

b. Start Of Day:

-   -   Density values of the product entered from the order module are         read by Terminal Filling Automation System (TFAS) and loaded         into the concerned meters automatically or from the program         manually. The filling is not started without verifying density         values. (These can be performed within day time on the condition         that all the related meters are to be in stand-by mode).     -   Before the filling is started, modes of all the meters (alarm,         failure, etc) are controlled by the system, and the meter cannot         be used for filling without remedying the failures.     -   If desired, opening report of the meters are taken in start of         day. Filling is allowed after meter totalizer (a counter which         is included in the meters and measures the data of how much         product has flowed) values are recorded.     -   On request, meter totalizer values can be taken automatically         during certain times determined by the system.     -   If there is a difference between end of day totalizer value and         start of day meter totalizer value opened within day time/start         of-day which are recorded by the automation, then the meter is         locked and filling cannot be started. The meter is opened for         sales by giving approval from filling automation program.

c. Filling Operations

-   -   Driver (or operator) makes entry by entering Barcode (PIN)         number written on the Product Request Bill to the display of         control equipment by pressing SET button in the electronic         control equipment.     -   In the electronic card filling systems, (CARD ID) card based for         order details are being read by card reader and then filling is         started.     -   In the compartment fillings, electronic control equipment         controls the PIN number from system and takes the data related         with the order and ask the COMPARTMENT number.     -   System reads the capacity of selected tanker's compartment and         product details proportional to the capacity of compartment         quantity comes to the screen. If it is desired, more lesser than         the compartment capacity can be written. However, it does not         permit to set more products bigger than the capacity of the         compartment. The filling is started by pressing Start button.     -   For other product requests in the delivery note, PIN and         COMPARTMENT number are re-entered and filling is continued. If         the filling of the compartment is ended by pressing PRINT button         for any reasons PIN number is asked for other compartments.     -   If the tanker will be filled fully with only a single product,         only COMPARTMENT number is asked for other compartments.     -   After all the products written in the delivery note are         delivered, filling computer compares the starting and ending         totalizer values with the given product quantity and flow to         fulfill the order is stopped in case such values are contravened         (does not give exit permission) and intervention of responsible         filling personnel is waited.

d. During filling;

-   -   Filling details and of the islands and tankers being filled are         shown in the screen of the system graphically and which island,         meter or delivery note have a problem are warned graphically and         in message. Filling logs are recorded.     -   In case of the problems to be experienced during filling,         responsible filling personnel stops the filling when necessary         and ends it manually using PC.     -   When the electronic control equipment communication is cut due         to failure, the values in the memory of electronic control         equipment are read and entered into the PC manually.

e. After filling:

-   -   Upon completion of the filling, its entry is deleted from the         TFAS screen automatically.     -   Product Delivery Receipt is given to tanker driver for         informative purposes while tanker is left.     -   Terminal Filling Automation Program (TFAP) receives Barcode         (PIN) No, Plate Number of Tanker, Compartment Capacities,         Product Details (product with and without additives), total         Product Quantity from FlashTech order module.     -   When the filling operation is completed, realized filling         information is entered into the system. Filling quantities are         transferred to order module for invoicing.

f. End of Day:

After the filling operations are completed; following reports are prepared;

-   -   Total sales on meter basis     -   Total sales on product basis     -   Total sales on total tankers' number basis     -   Total sales on customer/provider basis and a settlement for         tank, filling and selling (invoice) is done.

This invention enables monitoring of tanker filling operations in an automation environment staring from order stage until exit stage. Throughout the process, tanker's status can be determined by means of asking to the system about the status of any tanker at any time (during order, filling stage, etc).

The risk of giving the product from wrong meter or filling line is zeroized.

Electronic and mechanical failure information which may be arisen in filling equipments such as meter, control valve and temperature gauge can be taken from the Electronic control equipment and so it is possible to make immediate response to failure.

Filling operations is done on tanker's compartment basis. Compartment capacities pre-defined on the system are reflected on the meter automatically during filling operations. Potential product overflow/overspill is provided by loading quantity as much as desired compartment quantity.

Fillings which are halted due to power cut or as a result of any other reasons continue after such conditions caused such halting are finished and no information/data losses is occurred.

-   -   In the case that filling automation is whatsoever interrupted;         the filling can be made manually and after the conditions         returns to normal, filling details stored in the memory of the         meter can transferred to the system.     -   Tank/product stock calculation is kept and reported properly.     -   Product inputs and outputs can be monitored as tank movements         and volume and quantity of the product contained in the tank are         calculated in accordance with API tables by means of tank         calibration tables.     -   In the case that more than one company make fillings by using         the storage facilities of same terminal commonly, stock         monitoring on product owner company basis can easily be made.         With this feature, joint ventures can easily use the filling         terminals.     -   System input of tank measurement values are made directly and         automatically with automatic tank measurement system connection         through manually or automatically.     -   All the filling details and technical properties as well as         general details are stored in system memory. If required, it is         possible to access previous filling data.     -   By putting the system into service, it is contributed to         manpower and human health and environmental matters by         minimizing the filling time to a minimum level.     -   Filling operations and the details in the filling terminals at         various locations of the company can be spontaneously monitored         in the automation system from the principal office of the         company. 

1. This invention is an automation system and formed by the following operation steps: Entering order details via order module. Calling the respective driver of incoming orders which are communicated with ERP-DOS and similar communication programs for filling via announce module and directing relevant driver to filling island. Driver (or operator) enters the PIN number written over the Product Request Bill from display of meter. (Make his card be read at card reading system) Controls the meter PIN number via system and takes the concerned information regarding the request. Asks Tanker PIN code if necessary according to order type. Asks Driver PIN code if necessary according to order type. Asks compartment number. Sets the product quantity regarding that COMPARTMENT automatically. Filling is started by pressing Start button. Filling is continued by entering COMPARTMENT numbers again for other product requests given in delivery note. If the filling operation of the compartment is whatsoever finished by pressing PRINT button, PIN number is asked again for other COMPARTMENTS. If only one type product is going to be taken to the tanker, only COMPARTMENT number is asked for 2nd and 3rd compartments. After all the products written in the Product Request Bill is delivered, filling computer compares the starting and ending total quantities with given product quantity and in case of error, locks the meter for intervention by responsible filling personnel. Filling islands and tankers being filled are shown in the screen of the system graphically and in detail and which island, meter or delivery order have a problem are warned graphically and in color. Filling is finalized through computer screen by halting the filling when required. When meter communication is cut due to a failure, the values already stored in the memory of the meter are read and related tables are updated. In case the program is shut down due to power cuts or other reasons, data is stored in HDD. Upon completion of the order without any mistake, tanker graphic comes to its normal position on the meter screen. The data of realized filling are transferred to concerned units on product and compartment basis. Product Delivery Receipt is given to tanker driver for informative purposes while tanker is left. The order is locked if any troubles is occurred in the execution of work flow in filling terminal, user response is asked. Density values of the product entered from the order module are read by Terminal Filling Automation System (TFAS)and loaded into the concerned meters automatically or from the program manually. The filling is not started without verifying density values. (These can be performed within day time on the condition that all the related meters are to be in stand-by mode). Before the filling is started, modes of all the meters (alarm, failure, etc) are controlled by the system, and the meter cannot be used for filling without remedying the failures. If desired, opening report of the meters are taken in start of day. Filling is allowed after meter totalizer (a counter which is included in the meters and measures the data of how much product has flowed) values are recorded. On request, meter totalizer values can be taken automatically during certain times determined by the system. If there is a difference between end of day totalizer value and start of day meter totalizer value opened within day time/start of day which are recorded by the automation, then the meter is locked and filling cannot be started. The meter is opened for sales by giving approval from filling automation program. Driver (or operator) makes entry by entering Barcode (PIN) number written on the Product Request Bill to the display of control equipment by pressing SET button in the electronic control equipment. In the electronic card filling systems, (CARD ID) card based for order details are being read by card reader and then filling is started. In the compartment fillings, electronic control equipment controls the PIN number from system and takes the data related with the order and ask the COMPARTMENT number. System reads the capacity of selected tanker's compartment and product details proportional to the capacity of compartment quantity comes to the screen. If it is desired, more lesser than the compartment capacity can be written. However, it does not permit to set more products bigger than the capacity of the compartment. The filling is started by pressing Start button. For other product requests in the delivery note, PIN and COMPARTMENT number are re-entered and filling is continued. If the filling of the compartment is ended by pressing PRINT button for any reasons PIN number is asked for other compartments. If the tanker will be filled fully with only a single product, only COMPARTMENT number is asked for other compartments. After all the products written in the delivery note are delivered, filling computer compares the starting and ending totalizer values with the given product quantity and flow to fulfill the order is stopped in case such values are contravened (does not give exit permission) and intervention of responsible filling personnel is waited. Filling details and of the islands and tankers being filled are shown in the screen of the system graphically and which island, meter or delivery note have a problem are warned graphically and in message. Filling logs are recorded. In case of the problems to be experienced during filling, responsible filling personnel stops the filling when necessary and ends it manually using PC. When the electronic control equipment communication is cut due to failure, the values in the memory of electronic control equipment are read and entered into the PC manually. Upon completion of the filling, its entry is deleted from the TFAS screen automatically. Product Delivery Receipt is given to tanker driver for informative purposes when tanker is left. Terminal Filling Automation Program (TFAP) receives Barcode (PIN) No, Plate Number of Tanker, Compartment Capacities, Product Details (product with and without additives), total Product Quantity. When the filling operation is completed, filling information on compartment basis is entered into the system. Filling quantities are transferred to order module for invoicing. 